US8470619B2 - Selective decomposition of nitride semiconductors to enhance LED light extraction - Google Patents
Selective decomposition of nitride semiconductors to enhance LED light extraction Download PDFInfo
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- US8470619B2 US8470619B2 US12/909,548 US90954810A US8470619B2 US 8470619 B2 US8470619 B2 US 8470619B2 US 90954810 A US90954810 A US 90954810A US 8470619 B2 US8470619 B2 US 8470619B2
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
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- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
- H01L21/18—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic Table or AIIIBV compounds with or without impurities, e.g. doping materials
- H01L21/26—Bombardment with radiation
- H01L21/263—Bombardment with radiation with high-energy radiation
- H01L21/268—Bombardment with radiation with high-energy radiation using electromagnetic radiation, e.g. laser radiation
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10H—INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
- H10H20/00—Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
- H10H20/01—Manufacture or treatment
- H10H20/011—Manufacture or treatment of bodies, e.g. forming semiconductor layers
- H10H20/013—Manufacture or treatment of bodies, e.g. forming semiconductor layers having light-emitting regions comprising only Group III-V materials
- H10H20/0133—Manufacture or treatment of bodies, e.g. forming semiconductor layers having light-emitting regions comprising only Group III-V materials with a substrate not being Group III-V materials
- H10H20/01335—Manufacture or treatment of bodies, e.g. forming semiconductor layers having light-emitting regions comprising only Group III-V materials with a substrate not being Group III-V materials the light-emitting regions comprising nitride materials
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- H—ELECTRICITY
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- H10H—INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
- H10H20/00—Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
- H10H20/80—Constructional details
- H10H20/81—Bodies
- H10H20/819—Bodies characterised by their shape, e.g. curved or truncated substrates
- H10H20/82—Roughened surfaces, e.g. at the interface between epitaxial layers
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10H—INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
- H10H20/00—Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
- H10H20/80—Constructional details
- H10H20/81—Bodies
- H10H20/815—Bodies having stress relaxation structures, e.g. buffer layers
Definitions
- nitride UV LED structures high efficiencies, herein defined as achieving a high light output per unit of energy input is important.
- One method of improving LED efficiency is by improving the extraction efficiency of light from the LED structure.
- a thin template layer is formed between the substrate and the n-type AlGaN layer of the LED structure.
- This thin template layer helps match the substrate lattice structure to the n-type AlGaN layer lattice.
- the template layer may include a number of dislocations that do not propagate into the n-type AlGaN layer. These dislocations facilitate the relief of strain resulting from the mismatch between the lattices.
- the template layer also has an unintended and undesirable side effect.
- the smooth interface between the substrate and the template layer and a parallel second smooth surface between the n-type AlGaN layer and the template layer work together to form a waveguide.
- the template layer can act as a waveguide that channels light away from the direction of the intended LED output. Channeling light away from the intended LED direction results in lost photons, and a corresponding decrease in LED efficiency.
- a method of using a laser to texture a surface inside of a LED is described.
- the surface is typically located in or adjacent to a template layer of the LED.
- the textured surface helps prevent light from being trapped and eventually absorbed in the template layer thereby improving LED efficiency.
- the laser decomposes the material in the LED, typically AlGaN, to result in metal coated pitted structures.
- the material in the LED typically AlGaN
- metal coated pitted structures By arranging the pits such that the metal contacts a n-contact of the LED, current can be spread through the textured surface and thereby improve current spreading through the n-doped layer of the LED.
- FIG. 1 shows an example LED structure formed over a substrate.
- FIG. 2 shows the trapping of light in a template layer.
- FIG. 3 shows introducing pits into a template layer to prevent the trapping of light in the template layer.
- FIG. 4 shows the use of a texturing laser to create pits in a surface to be textured.
- FIG. 5 shows extending metal coated pits completely through the template layer to contact a re-contact of a LED to enable current spreading.
- FIGS. 6A and 6B show a matrix of lines in the template layer to spread current from a n-contact through the template layer.
- FIG. 7 shows positioning a surface to be textured at the interface of template layer and a n-doped LED layer.
- FIG. 8 shows forming two surfaces to be textured in a template layer, a first surface in the approximate center of the template layer and a second surface at the interface of the template layer and a n-doped LED layer.
- FIG. 9 a shows a prior art flow of current though a LED and FIG. 9 b shows metal coated pits in the n-doped layer used to enhance current spreading within this structure.
- FIG. 10 shows metal coated pits used to enhance light extraction from a LED backside.
- FIG. 1 shows an example LED structure 100 formed over a sapphire substrate 104 , however other substrate such as SiC or GaN are possible.
- the LED structure includes an intermediate template layer.
- Template layer 108 typically includes a nitride compound, usually GaN, AlN, InN, AlGaN, or InGaN, or AlInGaN.
- the template layer helps match the LED n-doped layer 112 lattice with the lattice of substrate 104 , typically a sapphire substrate.
- the template layer is typically thin, ranging in thickness between 0.1 and 10 micrometers.
- a light emitting diode including a n-doped layer 112 , a multiple quantum well active layer 116 and a p-doped layer 120 .
- An n-electrode 124 and a p-electrode 128 provide electron and hole currents, respectively, that flow into the active layer 116 to generate spontaneous emission of light.
- the p-electrode is usually formed from a material transparent to the light output by active layer 116 .
- typical transparent p-electrode material include ITO, NiO with embedded gold clusters and doped ZnO.
- template layer 108 can act as a light “trap” or waveguide.
- FIG. 2 shows that light 204 from an active region getting trapped in template layer 108 . Light “trapped” in template layer 108 is eventually absorbed and thus lost.
- FIG. 3 shows texturing at least one surface in or adjacent to the template layer to avoid trapping of light in the template layer 308 .
- the textured surface may be at the interface between the template layer and the substrate 304 .
- the textured surface may be at the interface between the template layer and the n-doped region.
- the textured surface may be at an intermediate material in an intermediate material layer within the template layer. Texturing an interface of the template layer or an intermediate material in the template layer disrupts the waveguiding effect and reflects some of the light back through the active layer and through the transparent p-contact.
- FIG. 4 shows the result of directing a texturing laser light 402 through substrate 404 to create a roughened interface.
- the texturing laser light frequency is selected such that the light is not absorbed in substrate 104 .
- the laser thus passes through the substrate and is absorbed by a surface in or adjacent to the template layer.
- One example of such a laser is a frequency tripled or frequency quadrupled YAG laser.
- a frequency quadrupled YAG laser typically has a wavelength of approximately 266 nm.
- Other possibilities are excimer lasers that output in the 193-308 nm frequency range.
- the laser is typically pulsed and focused such that the laser spot size area is less than 0.01 mm 2 .
- the laser intensity is adjusted such that the power density in the laser spot is between 50 J/cm 2 and 0.4 J/cm 2 .
- the intensity of the laser is sufficient to locally heat and decompose the surface to be textured.
- the small spot size of the laser at the surface to be textured is sufficiently small that pits 412 , 416 are created in the surface to be textured.
- the pits are created because the laser heats the material originally in pits 412 , 416 above a decomposition temperature thereby decomposing the compound semiconductor material originally in pits 412 , 416 , typically into a nitrogen gas and an alloy of group III metals (typically including one or more of aluminum, indium, and gallium). After material decomposition, a pit that has a depth of between 50 nm and 5 microns remains.
- pit shall be broadly defined to include any sort of indentation or cavity that results from the vaporized material. Although laser spots are typically oval in shape, as used herein “pit” is not limited to circular or oval shapes. For example, the “pit” may refer to a line or any other arbitrary shaped cavity created by the texturing laser. Viewed from the top, the “pit” also may be referred to as a “dimple”.
- the metal residue 420 coats the walls of each pit 412 , 416 or pit perimeter.
- material in the layer to be textured includes AlN, AlGaN, AlInN or AlInGaN
- aluminum will form a substantial portion of the metal residue 420 .
- Aluminum is an excellent UV reflector.
- the aluminum enhances the reflection of incident light from the textured layer thereby improving LED extraction efficiency by directing light along general direction 424 , out of the LED structure.
- the pattern of pits in the template layer typically includes unaffected regions 414 , herein defined as regions in the textured layer that are unaffected by the texturing laser. Such unaffected regions 414 are typically between adjacent pits. These unaffected regions remain undisturbed and continue to bond the LED structure to substrate 104 .
- the unaffected regions of the textured layer represents at least (25%) of the total area or the textured layer, or whatever is sufficient to prevent separation of the LED structure 100 from substrate 104 .
- FIG. 4 shows extraction of the LED light through the P-contact.
- FIG. 10 shows an alternative embodiment where the light is extracted from the back side of the LED structure along direction 1040 .
- the p-contact may be made from a reflective metal such as aluminum, silver, rhodium, or an ohmic metal mesh grid coupled with a reflective multi-layer stack as described in patent application Ser. No. 11/962,861 entitled Light Emitting Devices with an Electrical Active Top Reflector Contact by Chua et al. which is a continuation-in-part of U.S. application Ser. No. 11/516,333, both patent applications are hereby incorporated by reference.
- UV light escapes the LED structure at the un-decomposed regions between pits in the textured surface.
- the regions between pits that are unaffected by the texturing laser permit the light to pass from the template 1008 into the substrate 1004 and subsequently exit the LED.
- the unaffected regions of the textured surface will preferably exceed 50% of the total surface area with affected regions occupying only the minimum area necessary to prevent wave guiding in the template layer.
- FIG. 4 shows a uniform series of “pit” structures to texture the interface
- the pit pattern should not be so limited.
- the focused laser that textures the surface may be manipulated to form a variety of pit shapes including lines, dots or various other shapes. Shapes other than ovals formed by a laser spot may be accomplished by moving the texturing laser while it is outputting a beam. Alternately, the texturing laser may be moved and pulsed to form closely spaced and overlapping “oval pits” such that lines or other arbitrarily shaped cavities are formed by a combination of closely spaced overlapping oval shaped pits. Still other shapes may be formed using periodic patterns for which the dimensions are chosen to enhance efficiency through diffraction. For example, diffraction constructive and destructive interference can generate a pattern of bright and dark regions. Aligning corresponding bright and dark regions with transparent or opaque LED features can be used to maximize emission from the transparent features and minimize absorption at opaque features.
- the textured surface has been to redirect light
- the arrangement of pits or the pit shapes may be adjusted so that the metal residue 420 that forms over the pits acts as a current spreading layer that spreads current through the n-doped LED layer.
- Such current spreading layers are particularly useful for UV LEDs that utilize high aluminum content AlGaN for the n-doped layer due to the low electrical conductivity of high aluminum content AlGaN.
- FIG. 9 a shows a prior art LED structure without a low resistance pathway.
- current travels a lateral path 956 though n-doped layer 978 .
- the shortest distance between n-contact 912 and active region 980 can be as short as 2 microns, but is more typically 6-10 microns along.
- Semiconductor resistivity increases with increasing current densities, and increasing distances.
- the current can have to travel up to 100's of microns through the resistive n-doped layer 978 resulting in uneven current flow through active layer 980 and thus uneven light output in the active layer 980 thereby greatly reducing device efficiency.
- Providing a low resistance path at the back of the n-doped layer, even with the resistance incurred by passing thru the n-doped layer thickness twice, can significantly reduce the resistive losses and improve device efficiency.
- FIG. 9 b shows a side cross sectional view of LED providing a low resistance current path 976 using a line of intersecting pits.
- Each “Pit” 904 is initially formed by a texturing laser transmitting laser light through substrate 920 and the template layer 908 into the n-doped layer 978 where it is absorbed.
- the laser power delivered to the surface to be textured is insufficient to extend the resulting pit completely through the n-doped layer 978 to n contact 912 although alternate embodiments may allow such an extension.
- Metal 916 typically Aluminum, caused by decomposition of the AlN or AlGaN in n-doped layer 978 coats the pit surface. Close pit spacing results in metal coated pits overlap to form a low resistance electrical path 976 .
- the path the electrical current travels though the n-doped material in the direction of 974 to the highly conductive path 976 is very short.
- the n-doped region thickness is typically between 200 nm and 10 microns. The current thus traverses a similar thickness in direction 972 through the n-doped material to reach the LED active region 980 .
- the electrical current through the highly resistive n-doped layer of semiconductor is shortened to typically only between 400 nm to 20 microns.
- FIG. 5 shows a side cross sectional view and FIG. 6 shows a top view of one example of a textured surface in a template layer suitable for current spreading.
- FIG. 5 shows the pits 504 formed in the template layer 508 .
- FIG. 5 also shows the pits going all the way through to contact the n-contact 512 .
- the textured surface includes a grid of intersecting lines that carry current from the n-contact thorough the n-doped layer.
- FIG. 5 shows a side cross sectional view of the LED structure and the grid of intersecting lines.
- “Pit” 504 is initially formed by a texturing laser transmitting laser light through substrate 520 .
- the laser power delivered to the surface to be textured is sufficient to extend the resulting pit completely through the template layer 508 to n contact 512 .
- a metal 516 typically Aluminum, coats the surface of the pit.
- the metal 516 is generated by the decomposition of the AlN or AlGaN template layer 508 into Al metal or an Al/Ga metal alloy.
- the metal residue 516 forms a contact with n-contact 512 allowing current to easily flow from the n contact onto metal 516 where it can be spread throughout the template layer 508 .
- FIG. 6A shows a top view of the template layer 508 including the matrix of aluminum or the Al/Ga alloy grid lines.
- Pit 504 is a part of gridline line 620 which acts as a wire to carry current from n contact 512 .
- Various methods may be used to form gridline 620 .
- the laser forming pit 504 is pulsed. Relative motion between the laser and the template layer between pulses causes pits to overlap.
- FIG. 6B is an expanded view that shows closely spacing the pits 504 , 612 , 616 that substantially overlap to form a line. The spacing should be sufficiently close that the aluminum residue covering each pit sufficiently contacts the aluminum residue covering an adjacent pit such that electrical current flows easily between the adjacent pits.
- FIG. 6A shows forming a matrix of such lines of closely spaced pits.
- gridline 620 is part of a matrix of parallel gridlines 621 , 622 that intersect at a perpendicular angle with other parallel gridlines 624 , 628 to form a matrix of lines that distribute current throughout template layer 508 .
- Electrons flow from the n contact 512 , through the matrix of lines and into the n-doped semiconductor layer. From the n-doped semiconductor layer 112 , the electrons pass into the LED active region 116 where they recombine with holes from the p-contact generating light.
- FIGS. 5-6 show a matrix of lines, other patterns that distribute current throughout the template layer, this patent should not be limited as other patterns, may also be used to distribute current.
- FIGS. 1-6 show the surface to be textured occurring at the template layer and substrate interface, it should be understood that the texturing may also be formed at other surfaces in or adjacent to the template layer.
- FIG. 7 shows the texturing surface at the interface of the template layer 704 and the n-doped layer 712 of a LED structure heterostructure such that the pitting occurs in the n-doped layer 712 .
- Forming the pits or “features” in the N-doped layer may be accomplished by selecting a frequency of light that is absorbed by the n-doped semiconductor layer but is not absorbed by the template layer (alternately, the template layer material may be selected to be transparent to the texturing laser light).
- the template layer is made from a high aluminum content AlGaN which is transparent to the fourth harmonic output of a YAG laser (typically, the aluminum to gallium ratio exceeds 7 to 3).
- the laser light passes through both the sapphire substrate 700 and the AlGaN template layer 704 .
- the laser light strikes the n-doped semiconductor of the LED heterostructure 712 and is absorbed, pits 716 are formed in the surface 720 to be textured.
- Template layer interfaces are convenient places to locate a surface to be textured due to the natural material discontinuity. However, a surface to be textured may be located at other places in the template layer.
- FIG. 8 shows forming a surface 812 to be textured within template layer 804 .
- a material discontinuity formed within the template layer makes the region below surface 812 substantially transparent to the texturing laser. Regions above surface 812 substantially absorb the texturing laser energy. In one embodiment, this is accomplished by varying the aluminum content in an AlGaN template layer 804 . Pure GaN begins to absorb light at 362 nm and is transparent to light with a wavelength longer than this, while pure AlN begins to absorb light at 200 nm and is transparent to light with a wave length longer than this.
- the lower portion below surface 812 may be made transparent to the texturing laser light such that pits 820 or other structures form at surface 812 .
- FIG. 8 shows that a template layer may also include multiple surfaces to be textured.
- the interface between template layer 804 and LED n-doped layer 808 forms a second surface 816 to be textured.
- the laser wavelength needs to be changed.
- an AlGaN template layer 804 below surface 812 may have a very high concentration of aluminum, with a somewhat higher concentration of gallium above surface 812 such that a first texturing laser output is absorbed only at surface 816 and a second texturing laser output Is absorbed only at layer 812 .
- the “spacing” between adjacent pits in a surface (used to keep the layers from completely separating) can be “filled” by pits in a different surface.
- the unaffected region in a surface (“spaces”) between at least some pits prevents separation of substrate 800 from the LED n-doped layer 808 ; while the adjacent surfaces 812 , 816 minimize the smooth areas in the template layer that can trap light.
- Current spreading can also be improved by “filling” in such “spaces” using multiple textured surfaces to fill spacing between adjacent pits.
- LEDs operating in the UV region of the electromagnetic spectrum they may also be used at longer wavelengths as permitted by the nitride semiconductor material system. Such longer wavelengths may include parts of the visible spectrum including violet, blue, and green light.
- LEDs at these wavelength typically employ Ga and In rich alloys of AlGaN, InGaN, AlInN, and AlInGaN, and may include InN and GaN as well.
- the reflective and conductive Al metal and Al/Ga alloys may be replaced with In or Ga metal and Ga/In or Al/In alloys.
- SiC or GaN substrates may substitute for the sapphire substrate described.
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